Strange piston soak misfire experience

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May 7, 2018
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Northern KY
I've owned my 2009 Scion xB with the notorious oil-burning 2AZ-FE engine since January. Since that time I've driven it 7500 miles and have observed a moderate oil burn rate, so I planned to do a Berryman's soak at the next oil change. I did two full bottles at a 24 hour interval, then gave each cylinder a five second spray of fogging oil and (because it was pouring rain) let it set another 24 hours before installing a new set of Autolite double platinum spark plugs. One oddity I noticed while installing the plug in cylinder #2 was that I didn't feel the washer compress, it just bottomed out like you would expect from a plug that had been removed and reinstalled. I didn't think to look at the washer before installing it but the other three felt normal.

It took FOREVER to start! I was afraid I would overheat the starter so I took a break and hooked up my 10 amp charger (which pegged the needle) and waited a few minutes to try again. When it finally started it sputtered and rumbled like they usually do after a piston soak but smoothed out quite a bit. I let it run a few minutes and then proceeded with the oil change. All the normal dash indicators were lit up due to the misfires during startup.

After changing the oil I started it again to check for leaks and it was running much rougher, so much so that it was barely drivable and almost died going into drive. I pulled the codes and had cylinder 2 misfire and ignition circuit open codes. I removed the plug and inspected it but the only odd thing I saw was some carbon in the threads so I cleaned them off and reinstalled. I had a new Denso coil I had bought for the other xB so I went ahead and installed it and that immediately corrected the misfire. I'm not sure if the coil was actually bad or if the carbon (left in the threads from all the B12 that had been flung out of the dirty cylinder) had caused a faulty seal. Is that a thing? I figured the new coil was doing any good sitting in the box so I might as well swap it in in case it might matter.

Can moderately dirty spark plug threads cause enough of a compression leak to cause a misfire? Can just removing and reinstalling a coil kill it?

Also, a tip for people contemplating doing a piston soak: my experience now having done several of them is that an ounce of TCW-3 two stroke oil down the holes prior to starting is the best approach to reestablishing compression on a dry piston/cylinder. I won't use fogging oil again because it sure didn't seem to help much this time. When I used TCW-3 on two different engines they started noticeably faster than the times I didn't.
 
I dont understand why you would install new plugs on a just soaked engine loaded with oil and cleaner. Did you crank it with old plugs in or no plugs? Things can get tricky on pent roof 4V heads and long reach plugs. Easy to ingest dirt and cause more trouble.

Had you tried and of the new cleaning oils available? Seems like from ringland #3 and up is a better, safer aproach than top down
 
I dont understand why you would install new plugs on a just soaked engine loaded with oil and cleaner. Did you crank it with old plugs in or no plugs? Things can get tricky on pent roof 4V heads and long reach plugs. Easy to ingest dirt and cause more trouble.

Had you tried and of the new cleaning oils available? Seems like from ringland #3 and up is a better, safer aproach than top down
Berryman’s from the top is the proven solution for these engines. Prior to installing the plugs it gets cranked several times with a towel over the valve cover to catch all the junk that gets thrown out. I used Valvoline Restore & Protect for the refill.

This is the towel after the first 24 hours:

3E696546-670F-43B3-AAF9-4D47797A7176.webp
 
A bad o2 sensor won't hurt start-ability.

Should have used old plugs for the initial start up.

Hard telling what killed your coil pack. I killed one on a stick shift 02 camry, same engine, slightly different coil pack (depth), by going from coast to hammering the gas. They aren't perfect and carrying a spare is a great idea, like carrying a ballast resistor on your 78 Volare. If I had to say, "stress" killed it.
 
Also you have to keep plug insulators pristine clean, Dirty, sweaty fingerprints will lead to flashover. I usually wipe with everclear or acetone. Also if the terminals look varnished from the factory I will file or scotch bright the terminal in a limited fasion whre contct is expected to be made; Sometimes the COP spring pigtail contact wont chew through the varnish - Arco

p.s.: the rubber insert in the plug socket can be dirty also leading to flashover.
 
So, I always use the old plugs to get it started back up. Let it run until smoke is gone. Shut it down, change oil and spark plugs.

Before starting after a piston soak, I put an oz or so of Marvel Mystery Oil in each cylinder. Hand crank engine a turn. Put plugs back in. Let er rip!
 
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In a different thread I mentioned that I've seen experienced mechanics use WD40 to start diesel engines, and that it might be a good option after a piston soak.

About a week after that post, I had an opportunity to test my theory.
I had a weed eater that had been hanging in my garage for about 5 years. Needless to say it was totally dried out with no lube on the rings. After trying several times to start it, I tried starting fluid and tried again....nothing. Even tried a new plug, no go.

I put it aside for a few days, thinking it was a gonner. After all, I think I bought the thing around 1980 or so, from Sears!
Decided to try again after a few days, but this time I picked up the WD40 and sprayed some into the spark plug hole, reinstalled to plug, and pulled the cord.
It started on the first pull, and never quit! I went ahead and finished my little cutting that I need to do and it never missed a beat.
 
Also you have to keep plug insulators pristine clean, Dirty, sweaty fingerprints will lead to flashover. I usually wipe with everclear or acetone. Also if the terminals look varnished from the factory I will file or scotch bright the terminal in a limited fasion whre contct is expected to be made; Sometimes the COP spring pigtail contact wont chew through the varnish - Arco

p.s.: the rubber insert in the plug socket can be dirty also leading to flashover.
Good to know. That might also explain how the mysterious misfire in my other car went away after I replaced the valve cover gasket that was leaking into the spark tube.

Should have used old plugs for the initial start up.
I know, but it was threatening rain and (mostly) I was in a hurry. Also, I’ve never had an issue with plug fouling before so I figured it would probably be OK. I don’t think that was an issue here.
 
So, I always use the old plugs to get it started back up. Let it run until smoke is gone. Shut it down, change oil and spark plugs.

Before starting after a piston soak, I put an oz or so of Marvel Mystery Oil in each cylinder. Hand crank engine a turn. Put plugs back in. Let er rip!
If I may, what's the concern if you DONT change the plugs during a piston soak?
 
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